Method and device for the detection and processing of signals from industrial processes

ABSTRACT

A standard, modularly expandable system is for measuring and analyzing far spread signals from industrial processes consisting of several partial processes in an essentially feedback-free and synchronous manner. Random signals occurring in the partial processes are detected by way of measuring heads, optionally provided with a time stamp, and transferred to a measuring bus system in a predefined form as measuring signals or time signals. The measuring bus system is not identical with existing automation-related bus systems. The measuring signals and/or time signals are further processed by data concentrators. Evaluation units and/or display units that are local or indefinitely removed from the industrial process make it possible to further process or visualize measuring signals and/or time signals. The measuring heads detect a standard time signal such as the one of the global positioning system.

This application is the national phase under 35 U.S.C. § 371 of PCTInternational Application No. PCT/DE03/00093 which has an Internationalfiling date of Jan. 14, 2003, which designated the United States ofAmerica and which claims priority on German Patent Application number DE102 02 092.2 filed Jan. 21, 2002, the entire contents of which arehereby incorporated herein by reference.

FIELD OF THE INVENTION

The invention generally relates to a method for acquiring and processingsignals from industrial processes, and generally relates to a device.

BACKGROUND OF THE INVENTION

The acquisition and processing of signals from industrial processes formthe basis for central real-time evaluation and the support of analyticaland diagnostic functionalities both in situ and at a distance from therespective process. The latter is significant in particular for servicesof an equipment manufacturer such as, for example, remote monitoring andremote diagnostics.

The processes in question occur in industrial equipment which isgenerally composed of a plurality of equipment components which areusually spatially distributed. The processes in question are controlledand/or regulated by way of at least one automation device. The signalswhich are to be acquired and processed may originate from a very widevariety of sources and are present in any desired and different form,for example analog, binary, numerical, as video signals and/or asvariable physical parameters.

A suitable method and a device for carrying out such a method foracquiring and processing signals must pick up signals from a largenumber of sources, it being possible for the spatial distribution of thesources to be very extensive. A suitable method must sense measuringsignals precisely with continuously high quality and at the same timealso be able to support high sampling rates. Easy and rapid activationwith a low degree of complexity of wiring and configuration, as well asease of operation, comparable with the “plug and play” principle, areexpected from a corresponding device.

Especially if the individual partial processes of an industrial processare spatially distributed over a wide area, methods and devices foracquiring and processing signals from industrial processes are knownwhich are implemented by way of individual, different partial methodsand devices with respectively different performance spectrums andcharacteristics or by integration into existing control systems, orboth.

SUMMARY OF THE INVENTION

There is no overall system known which is composed of a uniform andmodular device which satisfies the previously specified requirements andwhich also permits synchronous and largely reaction-free acquisition ofthe signals present in the equipment. Methods for acquiring andprocessing signals from industrial processes in industrial equipmentwhich is preferably spatially distributed over a wide area and whichfulfills all the requirements mentioned above, and also is both capableof being used easily and universally and ensures precise, very largelyreaction-free and synchronous acquisition of signals, are also notknown.

An object of an embodiment of the invention is to make available amethod and a device for acquiring and processing signals from industrialprocesses in such a way that at least one of, and preferably both, theindicated requirements are fulfilled and at least one of the aforesaiddisadvantages are avoided.

An object may be achieved according to an embodiment of the invention bya method, and according to an embodiment of the invention by a device.

The method according to an embodiment of the invention and thecorresponding device are of uniform and modular design. The concept onwhich an embodiment of the invention is based is to separate measurementand analysis on the one hand, and control and regulation on the other.In particular, the implementation of this concept permits very largelyreaction-free acquisition of signals and the implementation of a uniformsystem of the type mentioned at the beginning which can be used invarious ways, is high in power and can be expanded in a modular andcost-effective way.

In one preferred embodiment of the method according to an embodiment ofthe invention, at least one measuring head receives, at the input end,measuring signals from any desired bus system. As a result, the verylargely reaction-free reception of the signals which are exchanged viathe bus system and/or the analysis of signal faults on the bus systemitself are made possible.

The method according to an embodiment of the invention canadvantageously be configured in such a way that at least one measuringhead passes on measuring signals at the output end directly to a dataconcentrator, as a result of which the modularity of the systemaccording to the invention is further increased.

According to one advantageous configuration of an embodiment of theinvention, the setup of the communication between data concentrators andmeasuring heads is carried out automatically using at least onecommunication unit. Both configurations decisively increase themodularity of the method which in this way can be expanded very easilyand at low cost and complexity.

In one preferred embodiment of the method according to an embodiment ofthe invention, time signals are generated by providing measuring signalswith a time stamp. As a result, an evaluation of the acquiredmeasurement signals is made considerably easier, specifically inparticular with respect to complex relationships which extend over aplurality of partial processes.

The method according to an embodiment of the invention is advantageouslyexpanded in such a way that at least one measuring head receives astandardized time signal. Using this time signal as a reference timepermits unambiguous and precise chronological assignment of measuringsignals beyond the boundaries of the individual process to which themethod according to the invention relates.

In a further configuration of the invention, the standardized timesignal is acquired from a Global Positioning System (GPS). The advantageof this configuration of an embodiment the invention is the worldwideavailability of GPS and the low costs which are associated with theacquisition of this standardized time signal.

According to a further advantageous configuration of the methodaccording to an embodiment of the invention, the time signals and/ormeasuring signals which originate from at least one data concentratorare processed using at least one programmable evaluation unit, it beingpossible for the programmable evaluation unit to be located at anydesired spatial distance from the partial processes. As a result, theflexibility and the universal applicability of the method are increased.The separation of tasks according to the concept which is provided forthe data concentrators and evaluation units means that resources areused particularly economically.

The method according to an embodiment of the invention can preferably beconfigured in such a way that at least one display unit is used todisplay data which is generated from the measuring signals and/or timesignals, it being possible for the display unit to be located at anydesired spatial distance from the partial processes. Such an expansionincreases modularity and flexibility of the method according to anembodiment the invention, the spatial independence of the display unitfrom the industrial partial processes also permits functionalities suchas remote analysis and as a result increases both the efficiency andeconomic viability of the intellectual evaluation of measuring resultsand makes it significantly easier to use expert knowledge forevaluation.

The method according to an embodiment the invention can be carried outby a device for acquiring and processing signals from industrialprocesses which are composed of at least one partial process, theindustrial process being controlled and/or regulated by at least oneautomation device which is equipped with one or more bus systems. Thedevice according to an embodiment of the invention includes at least onemeasuring bus system is provided which is not identical to the bussystem or systems of the automation device, and in that at least onemeasuring head for acquiring measuring signals is provided and isconnected at the input end to signal generators of the industrialprocess which are present and/or which are to be additionally provided,and at the output end passes on signals in a predefined form to themeasuring bus system, in that one or more data concentrators areconnected to the measuring bus system, and wherein a device are providedfor automatically detecting measuring heads and/or data concentrators.

In one advantageous configuration of the device according to anembodiment of the invention, at least one measuring head, which isconnected to a signal generator which supplies a standardized timesignal, is mounted on the upper termination of a device within which, orby which, the industrial process is carried out. This mounting permitsimproved reception of the standardized time signal if the latter istransmitted in a wire free fashion, in particular using a transmissiondevice which are not exclusively earth bound, for example satellites.

According to a further advantageous configuration of the deviceaccording to an embodiment of the invention, the data concentrators areconditioned so as to be capable of being expanded in such a way that therespectively required number of measuring bus systems and/or measuringheads can be connected to them. Measuring bus systems and/or measuringheads can therefore be connected in an uncomplicated way, saving timeand cost. In this way, the system can be expanded easily as desired.

BRIEF DESCRIPTION OF THE DRAWINGS

Further advantages, features and details of the invention will becomeevident from the description of illustrated exemplary embodiments givenhereinbelow and the accompanying drawings, which are given by way ofillustration only and thus are not limitative of the present invention,wherein:

FIG. 1 shows a schematic illustration of a measuring and analysis systemaccording to an embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 is a schematic illustration of a measuring and analysis systemfor an industrial process. In the example shown, the process is dividedinto two partial processes T1 and T2. Signals are to be acquired andprocessed within these partial processes T1 and T2.

Signal generators S1 to S6 (not illustrated in more detail) are locatedat the equipment components X1 to X3 and Y1 to Y3 and are connected tocorresponding measuring heads M1 to M6. The equipment components whichare illustrated by way of example in the drawing are the motors X1 to X4and the switchgear cabinets Y1 to Y4.

There are the bus systems P1 and P2 and further bus systems (notillustrated in more detail) which are to be assigned to the automationdevice of the industrial partial processes T1 and T2. The bus systems P1and P2 are used to control and regulate the equipment components X1 andY2 and X4 and Y4. As is shown by way of example on the bus system P2 andthe measuring head M7, measuring heads can also be connected to bussystems which are used for control and regulation.

The measuring heads M1 to M7 are connected at the output end to the dataconcentrators D1 and D2 using the measuring bus systems B1 and B2. Onetask of the data concentrators D1 and D2 is to process the time signalsand/or measuring signals of the measuring heads M1 to M7.

The evaluation units E1 and E2 are provided for further processing ofthe signals and data. The display units A1 and A2 make it possible todisplay measuring data which is processed by the data concentrators D1and D2 or the evaluation units E1 and E2. The evaluation units E1 andE2, the display units A1 and A2 and the data concentrators D1 and D2 areconnected to one another via local and/or spatially unlimited datatransmission networks C1 to C3.

Partial process in the sense of an embodiment of the invention may beunderstood to be, on the one hand, an actual partial process within anindustrial process. On the other hand, a partial process itself may beunderstood to be an industrial process so that two or more partialprocesses are equivalent in meaning to two or more industrial processes.As a result, for example one or more partial processes could be assignedto the fabrication process of an automobile manufacturer, while onefurther partial process could be the industrial process of a supplier.

One or more partial processes T1 and T2 in which signals are acquiredmay also be of a nonindustrial character. A partial process ofnonindustrial character may be understood to include but is not limitedto, for example, a process assigned to the private or public healthsystem, official authorities or institutions, private individuals,institutions for general welfare or generally institutions which areunderstood as not being associated with industry.

Partial processes T1 and T2 are defined in such a way that there is thepossibility that, within the scope of one or more partial processes T1and T2, nonindustrial equipment, such as, for example, magneticresonance tomographs, is connected to one or more measuring bus systemsB1 and B2.

In the exemplary embodiment, time signals are generated in thatmeasuring signals are provided with a synchronously running time stamp.

The measuring heads M1 to M7 are configured in such a way that theyreceive numerical, binary or analog signals from signal generators.However, measuring heads which acquire physical variables such as, forexample, oscillation period or temperature, and which are notillustrated in the drawing, are also provided. Measuring heads may beconnected to bus systems, for example PROFIBUS or CAN bus, which areused for controlling and regulating. The measuring head M7 which isconnected to the bus system P2 acquires data which is present on the bussystem P2 and which can be used to analyze signal faults on the bussystem P2, or make available further measuring data under theprecondition that this is carried out very largely without feedback andin a precisely timed way. The term precisely timed is understood to meansynchronous in the resolution of half the minimum sampling time.

All the measuring heads M1 to M7 are composed of a uniform bidirectionalcommunications part and have the functionalities for independentlyacquiring and generating the measuring data, and drivers for receivingdata from the data concentrator. The measuring bus systems B1 and B2 usea uniform transmission protocol and are uniformly based on opticalwaveguide technology in order to ensure minimum expenditure on cablingand configuration and a high degree of immunity to faults.

It is possible, but not illustrated in more detail, for measuring headsto be connected directly to a data concentrator D1 or D2. Thearrangement of data concentrator and of plugged-in measuring head thenresults in a unit which, under certain circumstances, is associated witha saving in space and cost. The data concentrators D1 and D2 aredesigned to be capable of being expanded in terms of the number ofmeasuring bus systems B1 and B2 which can be connected, and measuringheads which can be plugged directly.

Each of the data concentrators D1 and D2 includes at least one computingunit and at least one communications unit.

An object of the communications unit may include the independent,automatic operation of the measuring bus systems B1 and B2 of thedevice, the setup of the communication with the connected measuringheads M1 to M7 via the measuring bus systems B1 and B2, as well as theautomatic acquisition of the components which are located in the system,and the automatic monitoring of individual components for compatibility.In each communications unit, a structured storage matrix is madeavailable in which a uniquely defined address is present for eachmeasuring head which is assigned to the data concentrator and eachassigned measuring signal or time signal. The communications units alsomake it possible for the measuring processes of all the measuring headsand of all the data concentrators present in the system to besynchronized automatically with a common time base. Communications unitshave devices for self-diagnosis, devices for feeding in extraneoussignals and the functionality for automatic load distribution betweenthe data concentrators which are used in the system.

An object of the computing unit may include processing time signals andmeasuring signals. The computing unit carries out a chronologicalvectorization of the incoming data and archives the vectors on read onlymemories in order to prevent data losses. An object of the computingunit may further include taking into account different sampling rates,to smooth the measuring signals and, if necessary, interpolating commonsampling times.

The evaluation units E1 and E2 have functionalities for largelyprocessing measuring signals and time signals from different dataconcentrators D1 and D2. The evaluation units E1 and E2 can beprogrammed by the user by means of a graphic editor and have a libraryof functionalities, for example for filtering or transforming measuringsignals or signal vectors.

By way of the display units A1 and A2, it is possible to graphicallyrepresent selected measuring data in real time. The evaluation units E1and E2 and the display units A1 and A2 can be accessed both locally andalso by means of spatially limited or unlimited data transmissionnetworks. The evaluation units E1 and E2 support automatic monitoring byvirtue of the fact that they output messages when there arepredetermined data constellations in order, for example, to trigger analarm at at least one of the display units A1 and A2. This may becarried out, for example, using an e-mail or else also using a shortmessage via a mobile radio network.

While the measuring bus systems B1 and B2 are uniformly designed foroptical waveguide technology, this is not the case with the datatransmission networks C1 to C3. In the drawing, the data transmissionnetworks C1 and C3 constitute local networks with a high transmissionrate and use of the TCP/IP protocol family. The data transmissionnetwork C2 extends spatially over a significantly larger area andconstitutes a digital telecommunications network.

In one application example, the partial process T1 constitutes part ofthe fabrication process of an automobile manufacturer. Further, thepartial process T2 constitutes an industrial process at the factory of asupplier company. In spite of the process structures, which aredifferent here in both the partial processes T1 and T2, and in spite ofthe different automation systems, the analysis of systems and problemscan be carried out by way of the uniform system according to anembodiment of the invention.

Problems which extend beyond individual partial processes T1 and T2 canbe reliably detected and analyzed using the data concentrators D1 and D2and the evaluation units E1 and E2 and display units A1 and A2 which areprovided at a distance from the partial processes T1 and T2. Here, it ismade easier, for example, for external experts to carry out problemanalysis and to understand relationships by virtue of the fact thatmeasuring signals are provided with a time stamp which is based on auniform system time and is, if appropriate, standardized, which goesbeyond mere synchronization of the measuring signals.

When restructuring is carried out within the industrial process, themeasuring bus systems B1 and B2 and the measuring heads M1 to M7 caneasily be adapted to the new conditions brought about by therestructuring, or correspondingly expanded. The decoupling of themeasuring and analysis devices according to an embodiment of theinvention from existing automation devices of the industrial processalso permits not only a high degree of freedom from reaction during theacquisition of measuring data but also a uniform acquisition andanalysis of measuring data during restructuring within the industrialprocess. As a result, a direct comparison and the analysis of processfeatures before and after restructuring is made possible.

Exemplary embodiments being thus described, it will be obvious that thesame may be varied in many ways. Such variations are not to be regardedas a departure from the spirit and scope of the present invention, andall such modifications as would be obvious to one skilled in the art areintended to be included within the scope of the following claims.

1. A method for acquiring and processing signals from industrialprocesses including at least one partial process, the industrial processbeing at least one of controlled and regulated by at least oneautomation device equipped with at least one bus systems, that themethod comprising: using at least one measuring bus system which is notidentical to the at east one bus system of the automation device;acquiring measuring signals using at least one measuring head, themeasuring head acquiring measuring signals at an input end from signalgenerators of the industrial process which are at least one of presentand additionally provided and passing on these measuring signals at anoutput end to the measuring bus system in a predefined form; furtherprocessing the measuring signals by at least one data concentrator; andautomatically detecting at least one of measuring heads and dataconcentrators.
 2. The method as claimed in claim 1, wherein at least onemeasuring head (M7) receives, at the input end, measuring signals fromany desired bus system.
 3. The method as claimed in claim 1, wherein atleast one measuring head passes on measuring signals directly to a dataconcentrator at the output end.
 4. The method as claimed in claim 1,wherein the setup of the communication between data concentrators andmeasuring heads is carried out automatically using at least onecommunications unit.
 5. The method as claimed in claim 1, wherein allthe time signals are generated by providing measuring signals with atime stamp.
 6. The method as claimed in claim 1, wherein at least onemeasuring head receives a standardized time signal.
 7. The method asclaimed in claim 6, wherein the standardized time signal is acquiredfrom a Global Positioning System.
 8. The method as claimed in claim 7,wherein at least one of the time signals and measuring signals whichoriginate from at least one data concentrator are processed using atleast one programmable evaluation unit, the programmable evaluation unitbeing located at any desired spatial distance from the partialprocesses.
 9. The method as claimed in claim 8, wherein at least onedisplay unit is used to display data which is generated from at leastone of the measuring signals and time signals, the display unit beinglocated at any desired spatial distance from the partial processes. 10.A device for acquiring and processing signals from industrial processesincluding at least one partial process, the industrial process being atleast one of controlled and regulated by at least one automation deviceequipped with at least one bus system, that the device comprising: atleast one measuring bus system, which is not identical to the at leastone bus system of the automation device; at least one measuring head foracquiring measuring signals, connected at an input end to signalgenerators of the industrial process which are at least one of presentand additionally provided, and at an output end, passes on signals in apredefined form to the measuring bus system; at least one dataconcentrator, connected to the measuring bus system; and means forautomatically detecting at least one of measuring heads and dataconcentrators.
 11. The device as claimed in claim 10, wherein at leastone measuring head, connected at the input end to any desired bussystem, is provided.
 12. The device as claimed in claim 10, wherein atleast one measuring head, directly connected at the output end to a dataconcentrator, is provided.
 13. The device as claimed in claim 10 whereina communications unit, which permits the automatic setup of thecommunication between data concentrators and measuring heads, isprovided.
 14. The device as claimed in claim 10, wherein at least onemeasuring head, connected to a signal generator which supplies astandardized time signal, is provided.
 15. The device as claimed inclaim 14, wherein at least one of the measuring heads is mounted on theupper termination of a device within which, or by which, the industrialprocess is carried out.
 16. The device as claimed in claim 10, furthercomprising: at least one programmable evaluation unit, the programmableevaluation unit being located at any desired spatial distance from thepartial processes.
 17. The device as claimed in claim 14, furthercomprising: at least one display unit for displaying data generated fromat least one of the measuring signals and time signals, the display unitbeing located at any desired spatial distance from the partialprocesses.
 18. The device as claimed in claim 10, wherein the dataconcentrators are conditioned so as to be expandable in such a way thatthe at least one of the respectively required number of measuring bussystems and measuring heads are connectable to them.
 19. The method asclaimed in claim 6, wherein at least one of the time signals andmeasuring signals which originate from at least one data concentratorare processed using at least one programmable evaluation unit, theprogrammable evaluation unit being located at any desired spatialdistance from the partial processes.
 20. The method as claimed in claim1, wherein the measuring signals which originate from at least one dataconcentrator are processed using at least one programmable evaluationunit, the programmable evaluation unit being located at any desiredspatial distance from the partial processes.
 21. The method as claimedin claim 7, wherein at least one display unit is used to display datawhich is generated from at least one of the measuring signals and timesignals, the display unit being located at any desired spatial distancefrom the partial processes.
 22. The method as claimed in claim 6,wherein at least one display unit is used to display data which isgenerated from at least one of the measuring signals and time signals,the display unit being located at any desired spatial distance from thepartial processes.
 23. The method as claimed in claim 1, wherein atleast one display unit is used to display data which is generated fromthe measuring signals, the display unit being located at any desiredspatial distance from the partial processes.
 24. The device as claimedin claim 11, wherein at least one measuring head, directly connected atthe output end to a data concentrator, is provided.
 25. The device asclaimed in claim 10, further comprising: at least one display unit fordisplaying data generated from the measuring signals, the display unitbeing located at any desired spatial distance from the partialprocesses.
 26. A device for acquiring and processing signals fromindustrial processes including at least one partial process, theindustrial process being at least one of controlled and regulated by atleast one automation device equipped with at least one bus system, thatthe device comprising: at least one measuring bus system, which is notidentical to the at least one bus system of the automation device; meansfor acquiring measuring signals, connected at an input end to signalgenerators of the industrial process, and at an output end, for passingon signals in a predefined form to the measuring bus system; at leastone data concentrator, connected to the measuring bus system; and meansfor automatically detecting at least one of measuring heads and dataconcentrators.
 27. The device as claimed in claim 26, wherein the meansfor acquiring includes at least one measuring head, connected at theinput end to any desired bus system.
 28. The device as claimed in claim26, wherein the means for acquiring includes at least one measuringhead, directly connected at the output end to a data concentrator. 29.The device as claimed in claim 26, further comprising: means forpermitting automatic setup of the communication between dataconcentrators and measuring heads.
 30. The device as claimed in claim26, wherein the means for acquiring includes at least one measuringhead, connected to a signal generator which supplies a standardized timesignal.